Harley Davidson 2005 touring models. Service repair manual — page 1
2005 TOURING MODELS
SERVICE MANUAL
ELECTRICAL DIAGNOSTICS
Part Number 99483-05
Part Number 99495-05
Section 1: Maintenance
Section 1: Starting & Charging
Section 2: Chassis
Section 2: Instruments
Section 3: Engine
Section 3: TSM & TSSM
Section 4: Fuel System
Section 4: Engine Management
Section 5: Starter
Section 5: Engine Management (EFI)
Section 6: Drive
Section 6: Sound System
Section 7: Transmission
Section 7: Cruise Control
Section 8: Electrical
Section 8: Wiring
Section 9: Fuel Injection
Appendix
POLICE SERVICE SUPPLEMENT
FLHTCSE2 SERVICE SUPPLEMENT
Part Number 99483-05SP (FLT only)
Part Number 99500-05
Section 1: Maintenance
Section 1: Maintenance
Section 2: Chassis
Section 2: Chassis
Section 3: Engine (No content)
Section 3: Engine
Section 4: Fuel System (No content)
Section 4: Fuel System (No content)
Section 5: Starter (No content)
Section 5: Starter
Section 6: Drive (No content)
Section 6: Drive
Section 7: Transmission (No content)
Section 7: Transmission
Section 8: Electrical
Section 8: Electrical
Section 9: Fuel Injection (No content)
Section 9: Fuel Injection (No content)
Appendix
MAINTENANCE
1
Table Of Contents
SUBJECT
PAGE NO.
1.1 General
1-1
1.2 Maintenance Schedule
1-6
1.3 Engine Oil/Filter
1-9
1.4 Air Cleaner
1-11
1.5 Tires
1-13
1.6 Wheel Spokes
1-14
1.7 Primary Chain/Lubricant
1-15
1.8 Clutch Adjustment
1-17
1.9 Transmission Lubricant
1-19
1.10 Drive Belt
1-20
1.11 Throttle Cables
1-22
1.12 Enrichener Control
1-25
1.13 Fuel System
1-26
1.14 Brakes
1-28
1.15 Spark Plugs
1-29
1.16 Engine Idle Speed
1-30
1.17 Front Fork Oil
1-31
1.18 Steering Head Bearings
1-32
1.19 Critical Fasteners
1-33
1.20 Battery
1-35
1.21 Troubleshooting
1-36
HOME
GENERAL
1.1
REPAIR NOTES
Disassembly and Assembly
Always assemble or disassemble one part at a time. Do not
General maintenance practices are given in this section. All
work on two assemblies simultaneously. Be sure to make all
special tools and torque values are noted at the point of use
necessary adjustments. Recheck your work when finished.
and all required parts or materials can be found in the appro-
Be sure that everything is done.
priate PARTS CATALOG.
Operate the motorcycle to perform any final check or adjust-
ments. If all is correct, the motorcycle is ready to go back to
Safety
the customer.
Safety is always the most important consideration when per-
forming any job. Be sure you have a complete understanding
Checking Torques on Fasteners with Lock
of the task to be performed. Use common sense. Use the
proper tools. Don’t just do the job - do the job safely.
Patches
To check the torque on a fastener that has a lock patch:
Removing Parts
1.
Set the torque wrench for the lowest setting in the speci-
fied torque range.
Always consider the weight of a part when lifting. Use a hoist
whenever necessary. Do not lift heavy parts by hand. A hoist
2.
Attempt to tighten fastener to set torque. If fastener does
and adjustable lifting beam or sling are needed to remove
not move and lowest setting is satisfied (torque wrench
some parts. The lengths of chains or cables from the hoist to
clicks), then the proper torque has been maintained.
the part should be equal and parallel, and should be posi-
tioned directly over the center of the part. Be sure that no
obstructions will interfere with the lifting operation. Never
leave a part suspended in mid-air.
REPAIR AND REPLACEMENT
Always use blocking or proper stands to support the part that
PROCEDURES
has been hoisted. If a part cannot be removed, verify that all
bolts and attaching hardware have been removed. Check to
see if any parts are in the way of the part being removed.
Hardware and Threaded Parts
When removing hoses, wiring or tubes, always tag each part
Install helical thread inserts when inside threads in castings
to ensure proper installation.
are stripped, damaged or not capable of withstanding speci-
fied torque.
Cleaning
Replace bolts, nuts, studs, washers, spacers and small com-
mon hardware if missing or in any way damaged. Clean up or
If you intend to reuse parts, follow good shop practice and
repair minor thread damage with a suitable tap or die.
thoroughly clean the parts before assembly. Keep all dirt out
of parts; the unit will perform better and last longer. Seals, fil-
Replace all damaged or missing lubrication fittings.
ters and covers are used in this motorcycle to keep out envi-
Use Teflon tape on pipe fitting threads.
ronmental dirt and dust. These items must be kept in good
condition to ensure satisfactory operation.
Clean and inspect all parts as they are removed. Be sure all
Wiring, Hoses and Lines
holes and passages are clean and open. After cleaning,
cover all parts with clean lint-free cloth, paper or other mate-
Replace hoses, clamps, electrical wiring, electrical switches
rial. Be sure the part is clean when it is installed.
or fuel lines if they do not meet specifications.
Always clean around lines or covers before they are
removed. Plug, tape or cap holes and openings to keep out
dirt, dust and debris.
Instruments and Gauges
Always verify cleanliness of blind holes before assembly.
Replace broken or defective instruments and gauges.
Tightening screws with dirt, water or oil in the holes can
Replace dials and glass that are so scratched or discolored
cause castings to crack or break.
that reading is difficult.
2005 Touring: Maintenance
1-1
HOME
Bearings
Seals should not be removed unless necessary. Only remove
seals if required to gain access to other parts or if seal dam-
Anti-friction bearings must be handled in a special way. To
age or wear dictates replacement.
keep out dirt and abrasives, cover the bearings as soon as
Leaking oil or grease usually means that a seal is damaged.
they are removed from the package.
Replace leaking seals to prevent overheated bearings.
Wash bearings in a non-flammable cleaning solution. Knock
Always discard seals after removal. Do not use the same
out packed lubricant inside by tapping the bearing against a
seal twice.
wooden block. Wash bearings again. Cover bearings with
clean material after setting them down to dry. Never use com-
pressed air to dry bearings.
O-Rings (Preformed Packings)
Coat bearings with clean oil. Wrap bearings in clean paper.
Always discard O-rings after removal. Replace with new O-
rings. To prevent leaks, lubricate the O-rings before installa-
Be sure that the chamfered side of the bearing always faces
tion. Apply the same type of lubricant as that being sealed.
the shoulder (when bearings installed against shoulders).
Be sure that all gasket, O-ring and seal mating surfaces are
Lubricate bearings and all metal contact surfaces before
thoroughly clean before installation.
pressing into place. Only apply pressure on the part of the
bearing that makes direct contact with the mating part.
Gears
Always use the proper tools and fixtures for removing and
Always check gears for damaged or worn teeth.
installing bearings.
Remove burrs and rough spots with a honing stone or crocus
Bearings do not usually need to be removed. Only remove
cloth before installation. Lubricate mating surfaces before
bearings if necessary.
pressing gears on shafts.
Bushings
Shafts
If a shaft does not come out easily, check that all nuts, bolts
Do not remove a bushing unless damaged, excessively worn
or retaining rings have been removed. Check to see if other
or loose in its bore. Press out bushings that must be
parts are in the way before using force.
replaced.
Shafts fitted to tapered splines should be very tight. If shafts
When pressing or driving bushings, be sure to apply pres-
are not tight, disassemble and inspect tapered splines. Dis-
sure in line with the bushing bore. Use a bearing/bushing
card parts that are worn. Be sure tapered splines are clean,
driver or a bar with a smooth, flat end. Never use a hammer
dry and free of burrs before putting them in place. Press mat-
to drive bushings.
ing parts together tightly.
Inspect the bushing and the mated part for oil holes. Be sure
Clean all rust from the machined surfaces of new parts.
all oil holes are properly aligned.
Part Replacement
Gaskets
Always replace worn or damaged parts with new parts.
Always discard gaskets after removal. Replace with new gas-
kets. Never use the same gasket twice (unless instructed
CLEANING
otherwise). Be sure that gasket holes match up with holes in
the mating part.
If a gasket must be made, be sure to cut holes that match up
Part Protection
with the mating part. Serious damage can occur if any flange
Before cleaning, protect rubber parts (such as hoses, boots
holes are blocked by the gasket. Use material that is the right
and electrical insulation) from cleaning solutions. Use a
type and thickness.
grease-proof barrier material. Remove the rubber part if it
cannot be properly protected.
Lip Type Seals
Cleaning Process
Lip seals are used to seal oil or grease and are usually
installed with the sealing lip facing the contained lubricant.
Any cleaning method may be used as long as it does not
result in parts damage. Thorough cleaning is necessary for
Seal orientation, however, may vary under different applica-
proper parts inspection. Strip rusted paint areas to bare
tions.
metal before repainting.
1-2
2005 Touring: Maintenance
HOME
Rust or Corrosion Removal
Bearings
Remove rust and corrosion with a wire brush, abrasive cloth,
Remove shields and seals from bearings before cleaning.
sand blasting, vapor blasting or rust remover. Use buffing
Clean bearings with permanent shields and seals in solution.
crocus cloth on highly polished parts that are rusted.
Clean open bearings by soaking them in a petroleum clean-
ing solution. Never use a solution that contains chlorine.
Let bearings stand and dry. Do not dry using compressed air.
Do not spin bearings while they are drying.
2005 Touring: Maintenance
1-3
HOME
TOOL SAFETY
PUNCHES/CHISELS
● Never use a punch or chisel with a chipped or mush-
roomed end; dress mushroomed chisels and punches
AIR TOOLS
with a file.
● Always use approved eye protection equipment when
● Hold a chisel or a punch with a tool holder if possible.
performing any task using air-operated tools.
● When using a chisel on a small piece, clamp the piece
● On all power tools, use only recommended accessories
firmly in a vise, and chip toward the stationary jaw.
with proper capacity ratings.
● Wear approved eye protection when using these tools.
● Do not exceed air pressure ratings of any power tools.
● Protect bystanders with approved eye protection.
● Bits should be placed against work surface before air
hammers are operated.
SCREWDRIVERS
● Disconnect the air supply line to an air hammer before
attaching a bit.
● Don’t use a screwdriver for prying, punching, chiseling,
scoring, or scraping.
● Never point an air tool at yourself or another person.
● Use the right type of screwdriver for the job; match the
● Protect bystanders with approved eye protection.
tip to the fastener.
● Don’t interchange POZIDRIV®, PHILLIPS®, or REED
WRENCHES
AND PRINCE screwdrivers.
● Screwdriver handles are not intended to act as insula-
● Never use an extension on a wrench handle.
tion; don’t use on live electrical circuits.
● If possible, always pull on a wrench handle and adjust
● Don’t use a screwdriver with rounded edges because it
your stance to prevent a fall if something lets go.
will slip - redress with a file.
● Never cock a wrench.
● Never use a hammer on any wrench other than a Strik-
RATCHETS AND HANDLES
ing Face wrench.
● Periodically clean and lubricate ratchet mechanisms with
● Discard any wrench with broken or battered points.
a light grade oil. Do not replace parts individually; ratch-
● Never use a pipe wrench to bend, raise, or lift a pipe.
ets should be rebuilt with the entire contents of service
kit.
● Never hammer or put a pipe extension on a ratchet or
PLIERS/CUTTERS/PRYBARS
handle for added leverage.
● Plastic or vinyl covered pliers handles are not intended
● Always support the ratchet head when using socket
to act as insulation; don’t use on live electrical circuits.
extensions, but do not put your hand on the head or you
● Don’t use pliers or cutters for cutting hardened wire
may interfere with the action of its reversing mechanism.
unless they were designed for that purpose.
● When breaking loose a fastener, apply a small amount
● Always cut at right angles.
of pressure as a test to be sure the ratchet’s gear wheel
is engaged with the pawl.
● Don’t use any prybar as a chisel, punch, or hammer.
SOCKETS
HAMMERS
● Never use hand sockets on power or impact wrenches.
● Never strike one hammer against a hardened object,
● Select the right size socket for the job.
such as another hammer.
● Always grasp a hammer handle firmly, close to the end.
● Never cock any wrench or socket.
● Select only impact sockets for use with air or electric
● Strike the object with the full face of the hammer.
impact wrenches.
● Never work with a hammer which has a loose head.
● Replace sockets showing cracks or wear.
● Discard hammer if face is chipped or mushroomed.
● Keep sockets clean.
● Wear approved eye protection when using striking tools.
● Always use approved eye protection when using power
● Protect bystanders with approved eye protection.
or impact sockets.
1-4
2005 Touring: Maintenance
HOME
STORAGE UNITS
● Don’t open more than one loaded drawer at a time.
Close each drawer before opening up another.
● Close lids and lock drawers and doors before moving
storage units.
● Don’t pull on a tool cabinet; push it in front of you.
● Set the brakes on the locking casters after the cabinet
has been rolled to your work.
2005 Touring: Maintenance
1-5
HOME
MAINTENANCE SCHEDULE
1.2
The table below lists the maintenance requirements for Tour-
required specifications. If more detailed information is
ing models. If you are familiar with the procedures, just refer
needed, turn to the sections which follow for step-by-step
to the table for the recommended service interval. If neces-
instructions.
sary, see the quick reference table on the next page for the
Table 1-1. Scheduled Maintenance Intervals
1000
5000
10,000
15,000
20,000
25,000
mi
mi
mi
mi
mi
mi
ITEM
PROCEDURE
NOTES
1600
8000
16,000
24,000
32,000
40,000
km
km
km
km
km
km
Engine oil and filter
Replace
X
X
X
X
X
X
Oil lines and brake system
Inspect for leaks
X
X
X
X
X
X
1
Air cleaner
Inspect, service as required
X
X
X
X
X
X
Tires
Check pressure, inspect tread
X
X
X
X
X
X
Wheel spokes
Check tightness
X
X
X
1, 4
Primary chain tension
Check adjustment
X
X
X
X
X
X
Primary chaincase lubricant
Replace
X
X
X
X
X
X
Clutch
Check adjustment
X
X
X
X
X
X
1
Transmission lubricant
Replace
X
X
X
X
X
X
Drive belt and sprockets
Inspect, adjust belt
X
X
X
X
X
X
1
Throttle, brake, clutch and
Check, adjust and lubricate
X
X
X
X
X
X
1, 4
enrichener controls
Jiffy stand
Inspect and lubricate
X
X
X
1
Fuel valve, lines and fittings
Inspect for leaks
X
X
X
X
X
X
1, 4
Fuel filter
Clean (EFI: replace)
X
1
Brake fluid
Check levels and condition
X
X
X
X
X
X
Brake pads and discs
Inspect for wear
X
X
X
X
X
X
Inspect
X
X
X
X
Spark plugs
Replace
X
X
Electrical equipment
Check operation
X
X
X
X
X
X
and switches
Engine idle speed
Check adjustment
X
X
X
X
X
X
1
Front fork oil
Replace
X
1
Steering head bearings
Adjust and lubricate
X
X
X
1, 2
Windshield bushings
Inspect
X
X
1
Fuel door, Tour-pak,
Lubricate hinges and latches
X
X
X
X
X
saddlebags
Critical fasteners
Check tightness
X
X
X
1
Engine mounts and
Inspect
X
X
1
stabilizer links
Battery
Check battery and clean connections
3
Road test
Verify component and system functions
X
X
X
X
X
X
NOTES:
1.
Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are
mechanically qualified.
2. Disassemble, lubricate and inspect every 30,000 miles (48,000 km).
3. Perform annually.
4. Not all vehicles are equipped with enrichener, fuel valve or spoke wheels.
1-6
2005 Touring: Maintenance
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Table 1-2. Quick Reference Data
ITEM
SPECIFICATION
DATA
Drain plug torque
14-21 ft-lbs (19-28 Nm)
Oil capacity
4 qt. (3.8 L)
Engine oil and filter
Filter
Hand tighten 1/2-3/4 turn after gasket contact
Chrome filter part number
63798-99
Black filter part number
63731-99
Air cleaner cover bracket screw torque
20-40 in-lbs (2-5 Nm)
Air cleaner cover screw torque
36-60 in-lbs (4-7 Nm)
Air cleaner
Loctite Medium Strength Threadlocker
243
Air cleaner cover screw threadlocker
(blue), Part No. 99642-97 (6 ml)
Pressure: solo rider
Front: 36 psi (2.5 bar), Rear: 36 psi (2.5 bar)
Pressure: rider with passenger
Front: 36 psi (2.5 bar), Rear: 40 psi (2.8 bar)
Tire condition and pressure
Replace tire if 1/32 in. (0.8 mm) or less
Wear
of tread pattern remains
Wheel spokes
Spoke nipple torque
40-50 in-lbs (4.5-5.6 Nm)
Deflection with engine cold
5/8-7/8 in. (15.9-22.2 mm)
Deflection with engine hot
3/8-5/8 in. (9.5-15.9 mm)
Primary chain tension
Chain tensioner nut torque
21-29 ft-lbs (29-39 Nm)
Primary chain inspection cover torque
84-108 in-lbs (10-12 Nm)
Lubricant capacity
32 oz (946 mL)
Primary chaincase drain plug torque
36-60 in-lbs (4-7 Nm)
Primary chaincase lubricant
Primary Chaincase Lubricant part
99887-84 (qt), 99886-84 (gal)
numbers
Free play at adjuster screw
1/2-1 turn
Free play at hand lever
1/16-1/8 in. (1.6-3.2 mm)
Clutch adjustment
Adjuster screw locknut torque
72-120 in-lbs (8-14 Nm)
Clutch inspection cover torque
84-108 in-lbs (10-12 Nm)
Dipstick at FULL with motorcycle level
Lubricant level
and filler plug resting on threads
Lubricant capacity
20-24 oz (590-710 mL)
Transmission lubricant
Semi-Synthetic Transmission Lubricant
99892-84 (qt), 98853-96 (case of qt’s)
part numbers
99891-84 (gal), 98852-96 (case of gal’s)
Transmission drain plug torque
14-21 ft-lbs (19-28 Nm)
Filler plug torque
25-75 in-lbs (3-9 Nm)
Upward force at midpoint of bottom belt
10 lb. (4.5 kg)
strand
Deflection with motorcycle on jiffy stand
Drive belt
without rider or luggage and 10 psi (69
1/4 - 5/16 in. (6.4-7.9 mm)
kPa) in rear shocks
Deflection with motorcycle upright and
3/16 - 1/4 in. (4.8-6.4 mm)
rear wheel in the air
Lubricant part number
Super Oil, 94968-85TV (1/4 fl. oz)
Throttle and clutch cables
Handlebar clamp screw torque
60-80 in-lbs (6.8-9.0 Nm)
Handlebar switch housing screw torque
35-45 in-lbs (4-5 Nm)
Enrichener control
Hex nut torque
20-35 in-lbs (2-4 Nm)
Fuel filter
Hex jam nut torque
15-20 ft-lbs (20-27 Nm)
DOT 4 Brake Fluid part number
99953-99A (12 oz)
Brake Fluid Reservoir Level
Level
1/ 8 inch (3.2 mm) from the top
Master cylinder reservoir cover torque
6-8 in-lbs (0.7-0.9 Nm)
Minimum brake pad thickness
0.04 in. (1.02 mm)
Brake pad linings and discs
Minimum brake disc thickness
See stamp on side of disc
2005 Touring: Maintenance
1-7
HOME
Table 1-2. Quick Reference Data
ITEM
SPECIFICATION
DATA
Type
HD-6R12
Spark plugs
Gap
0.038-0.043 in. (0.97-1.09 mm)
Torque
12-18 ft-lbs (16-24 Nm)
Engine idle speed
Idle speed
950-1050 rpm
Hydraulic Fork Oil (Type E) part number
99884-80 (16 oz)
Front Fork Oil
Amount
See Section 2.15
Special Purpose Grease, 99857-97
Steering head bearings
Neck fitting lubricant
(14 oz cartridge)
Critical fasteners, engine
See Section 1.19
mounts and stabilizer links
Lubricant part number
Electrical Contact Lubricant, 99861-02 (1 oz)
Battery
Terminal bolt torque
60-96 in-lbs (6.8-10.9 Nm)
Hold-down clamp screw torque
15-20 ft-lbs (20-27 Nm)
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2005 Touring: Maintenance
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ENGINE OIL/FILTER
1.3
GENERAL
f1641x3x
See Section
1.2 MAINTENANCE SCHEDULE for the
required service interval.
NOTE
If the motorcycle is ridden hard, under dusty conditions, or in
cold weather, the engine oil and filter should be changed
more often.
PROCEDURE
1. Ride motorcycle until engine is at normal operating tem-
perature.
2. Locate oil filler plug/dipstick on right side of motorcycle
at top of transmission case. To remove the oil filler plug,
pull steadily while moving plug back and forth.
3. Locate oil drain plug at front left side of the oil pan.
Remove the oil drain plug and allow oil to drain com-
pletely.
Figure 1-1. Remove Engine Oil Filter
4. Inspect the oil drain plug O-ring for cuts, tears or signs of
deterioration. Replace as necessary.
9. With motorcycle resting on jiffy stand, add 3-1/2 quarts
5. Remove the oil filter as follows:
(3.3 liters) engine oil as specified in Table 1-3. Use the
a. Obtain the OIL FILTER WRENCH (HD-42311). The
proper grade of oil for the lowest temperature expected
tool allows easy removal of the oil filter without risk
before the next oil change.
of damage to the crankshaft position sensor or
cable.
Table 1-3. Recommended Engine Oils
b. Place the jaws of the wrench over the oil filter with
the tool oriented vertically. See Figure 1-1.
Harley-
Lowest
Cold Weather
Harley-Davidson
Viscosity
Davidson
Ambient
Starts Below
c. Using a 3/8 inch drive with a 4 inch extension, turn
Type
Rating
Temperature
50˚F (10˚C)
wrench in a counterclockwise direction. Do not use
with air tools.
SAE
Below 40˚F
HD Multi-grade
HD 360
Excellent
10W40
(4˚C)
NOTE
SAE
Above 40˚F
HD Multi-grade
HD 360
Good
20W50
(4˚C)
Use OIL FILTER WRENCH (HD-44067) if HD-42311 is not
SAE
Above 60˚F
available.
HD Regular Heavy
HD 360
Poor
50
(16˚C)
6. Clean the oil filter mount flange of any old gasket mate-
SAE
Above 80˚F
HD Extra Heavy
HD 360
Poor
60
(27˚C)
rial.
7. Lubricate gasket with clean engine oil and install new oil
filter on filter mount. Hand tighten oil filter 1/2-3/4 turn
CAUTION
after gasket first contacts filter mounting surface. Do
NOT use OIL FILTER WRENCH for oil filter installation.
Oil level cannot be accurately measured on a cold
engine. For preride inspection, with motorcycle leaning
NOTE
on jiffy stand on level ground, oil should register on dip-
Use of the Premium 10 micron synthetic media oil filter is
stick between arrows when engine is cold. Do NOT add
highly recommended, Part No. 63798-99 (Chrome) or 63731-
oil to bring the level to the FULL mark on a COLD engine.
99 (Black).
8. Install engine oil drain plug and tighten to 14-21 ft-lbs
10. Perform engine oil level COLD CHECK as follows:
(19-28 Nm).
2005 Touring: Maintenance
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HOME
COLD CHECK
HOT CHECK
f1254b3x
Figure 1-2. Engine Oil Dipstick
a. With the motorcycle resting on the jiffy stand on
c. Wipe off the dipstick and insert it back into the oil
level ground, wipe off the dipstick and insert it back
pan with the plug pushed completely into the fill
into the oil pan with the plug pushed completely into
spout.
the fill spout.
d. Remove the dipstick and note the level of the oil.
b. Remove the dipstick and note the level of the oil. Oil
Add only enough oil to bring the level to the FULL
level should register between the two arrows on the
mark on the dipstick. See Figure 1-2. Do not overfill.
dipstick. See Figure 1-2. If oil level is at or below the
lower arrow, add only enough oil to bring the level
between the two arrows on the dipstick.
12. Start engine and carefully check for leaks around hoses,
drain plug and oil filter.
11. Perform engine oil level HOT CHECK as follows:
a. Ride motorcycle until engine is at normal operating
temperature.
b. With the motorcycle resting on the jiffy stand on
level ground, allow engine to idle for 1-2 minutes.
Turn engine off.
1-10
2005 Touring: Maintenance
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AIR CLEANER
1.4
7.
Inspect the breather tubes and rubber seal for cuts,
GENERAL
tears, holes or signs of deterioration. Replace as neces-
sary. Direct compressed air through the breather tubes
See Section
1.2 MAINTENANCE SCHEDULE for the
to be sure that they are not plugged.
required service interval.
8.
Clean the filter element as follows:
a. Wash the filter element in warm, soapy water. To
PROCEDURE
remove soot and carbon, soak element for 30 min-
utes in warm water with mild detergent.
1. Remove large allen head socket screw in center of air
cleaner cover. Remove air cleaner cover with rubber
seal. See Figure 1-3.
1WARNING
2. Remove three T27 TORX screws to release cover
Do not use gasoline or solvents to clean the filter ele-
bracket from filter element.
ment. Volatile or flammable cleaning agents may cause
an intake system fire, which could result in death or seri-
ous injury.
CAUTION
Never run the engine with the filter element removed.
1WARNING
The filter prevents dirt and dust from entering the
engine.
Compressed air can pierce the skin and cause injury.
Never use your hand to check for leaks or to determine
3. Remove filter element pulling two breather tubes from
air flow rates. Wear safety glasses to shield your eyes
holes on inboard side.
from flying dirt and debris. Failure to comply could result
4. Remove gasket from sleeve on inboard side of filter ele-
in death or serious injury.
ment. Discard gasket.
b. Dry the filter element using low pressure com-
5. Remove breather tubes from fittings on two cylinder
pressed air (32 psi/221 kPa maximum). Rotate the
head breather bolts.
element while moving air nozzle up and down the
6. Thoroughly clean air cleaner cover, breather tubes and
element interior. Do not rap the element on a hard
backplate with warm, soapy water.
surface.
8
5
3
4
2
7
9
6
1
1. Cover Screw
4. T27 Torx Screw (3)
7.
Gasket
2. Air Cleaner Cover
5. Cover Bracket
8.
Breather Tube (2)
3. Rubber Seal
6. Filter Element
9.
Backplate
f1721x4x
Figure 1-3. Air Cleaner Assembly
2005 Touring: Maintenance
1-11
HOME
c. Hold the filter element up to a strong light source.
12. Place filter element onto backplate with the flat side
The element can be considered sufficiently clean if
down, so that hole on inboard side of element fits over
light is uniformly visible through the media.
molded boss in backplate.
NOTE
13. Align holes in cover bracket with those in filter element
Replace the filter element if damaged or if filter media cannot
and start three T27 TORX screws. Stamp on cover
be adequately cleaned.
bracket points to downside. Alternately tighten screws to
20-40 in-lbs (2.3-4.5 Nm) in a crosswise pattern.
9.
Slide new gasket over sleeve on inboard side of filter
element. Be sure holes in gasket are aligned with those
14. Verify that rubber seal is properly seated around perime-
in filter.
ter of air cleaner cover.
10. Insert breather tubes about 1/4 inch (6.4 mm) into holes
on inboard side of filter element.
15. Fit air cleaner cover into backplate. Apply a small dab of
Loctite Medium Strength Threadlocker
243 (blue) to
11. Install breather tubes onto fittings of two cylinder head
threads of large allen head socket screw. Install screw in
breather bolts.
center of air cleaner cover. Tighten screw to 36-60 in-lbs
NOTE
(4.1-6.8 Nm).
Air cleaner mounting without installation of the breather
tubes allows crankcase vapors to be vented into the atmo-
sphere in violation of legal emissions standards.
1-12
2005 Touring: Maintenance
HOME
TIRES
1.5
GENERAL
o0250xox
See Section
1.2 MAINTENANCE SCHEDULE for the
required service interval.
Sidewall
Arrow
PROCEDURE
1. Inspect for wear as follows:
a. Locate the arrows on the tire sidewalls. The arrows
point to location of the tread wear indicator bars.
See upper frame of Figure 1-4.
b. Immediately replace tires if any tread wear indicator
bar is on the tire tread surface, indicating that 1/32
inch (0.8 mm) or less of tire tread pattern remains.
Indicator Bar on
See lower frame of Figure 1-4.
Tread Surface
NOTE
Harley-Davidson recommends that the tires be replaced
BEFORE the tread wear indicator bars are on the tire tread
surface.
o0249xox
2. Inspect for damage. Replace tires if:
Figure 1-4. Tread Wear Indicator Bars
● Cords or fabric become visible through cracked
sidewalls, snags or deep cuts.
● Bump, bulge or split line is observed.
● Puncture, deep cut or other damage is present that
is not repairable.
3. Check tire pressure.
Table 1-4. Tire Pressure (Cold)
FRONT
REAR
DUNLOP TIRES ONLY
PSI
BARS
PSI
BARS
Solo Rider
36
2.5
36
2.5
Rider & One Passenger
36
2.5
40
2.8
1WARNING
Do not inflate tires beyond the maximum inflation pres-
sure specified on tire sidewall. Overinflation can lead to
tire failure while vehicle is in operation, which could
result in death or serious injury.
2005 Touring: Maintenance
1-13
HOME
WHEEL SPOKES
1.6
2.
Lightly tap each spoke with a spoke wrench. Loose
GENERAL
spokes will sound dull and must be tightened. Tighten
spokes to 40-50 in-lbs (4.5-5.6 Nm). If more than a few
See Section
1.2 MAINTENANCE SCHEDULE for the
spokes are loose, true the entire wheel following the pro-
required service interval.
cedure under Section 2.7 TRUING LACED WHEEL.
PROCEDURE
1.
Raise wheel off the ground.
CAUTION
If nipples require more than one full turn to tighten
spoke, remove tire to check that spoke protrusion has
not damaged tube.
1-14
2005 Touring: Maintenance
HOME
PRIMARY CHAIN/LUBRICANT
1.7
GENERAL
f1210x6x
See Section
1.2 MAINTENANCE SCHEDULE for the
required service interval.
1
1
4
Clutch
3
PROCEDURE
4
Inspection
Primary
Cover
Chain
2
5
Inspection
Cover
PRIMARY CHAIN ADJUSTMENT
2
3
1.
Remove seat. See Section 2.24 SEAT, REMOVAL.
Drain Plug
1WARNING
To protect against shock and accidental start-up of
Figure 1-5. Primary Chaincase Cover
motorcycle, disconnect the negative battery cable before
proceeding. Inadequate safety precautions could result
f1841x6x
in death or serious injury.
Top
2.
Unthread bolt and remove battery negative cable (black)
Center
from battery negative (-) terminal.
Nut
3. See Figure 1-5. Using a T27 TORX drive head, remove
four screws to free the primary chain inspection cover
Chain Inspection
from the primary chaincase cover.
Cover Opening
4. Check the primary chain tension. Push on the upper
strand to verify that it has free up and down movement
midway between the engine compensating sprocket
(front) and the clutch sprocket (rear).
5.
Measure the free play to be sure that it falls within the
range specified for a hot or cold engine. See Table 1-5.
Table 1-5. Primary Chain Adjustment
Figure 1-6. Primary Chaincase Cover
(Free Play)
Inches
Millimeters
NOTE
COLD ENGINE
5/8-7/8 inch
15.9-22.2 mm
As chains stretch and wear, they run tighter at one spot than
3/8-5/8 inch
9.5-15.9 mm
HOT ENGINE
another. Always adjust the free play at the tightest spot in the
chain. Replace the primary chain if it is worn to the point
where it cannot be properly adjusted.
6.
If the chain is too tight or too loose, then adjust as fol-
lows:
CAUTION
a. Locate the chain tensioner assembly and loosen the
Always keep the primary chain properly adjusted. Allow-
top center nut a maximum of two turns. See Figure
ing the chain to run too tight or too loose will result in
1-6.
excessive chain and sprocket wear.
b. Raise or lower the chain tensioner assembly as
c. Tighten the top center nut of the chain tensioner
necessary to obtain the specified free play.
assembly to 21-29 ft-lbs (29-39 Nm).
2005 Touring: Maintenance
1-15
HOME
7.
Align holes in new gasket with holes in the primary
chaincase cover. Using a T27 TORX drive head, install
Primary
four screws to secure primary chain inspection cover to
Chaincase Cover
primary chaincase cover. Alternately tighten screws to
84-108 in-lbs (10-12 Nm) in a crosswise pattern. See
Figure 1-5.
8.
Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
9.
Install seat. See Section 2.24 SEAT, INSTALLATION.
PRIMARY CHAIN LUBRICANT
1. Using a T27 TORX drive head, remove five screws (with
captive washers) to free clutch inspection cover from pri-
Lubricant
mary chaincase cover.
f2301x6x
2. Remove magnetic drain plug at bottom of primary chain-
case cover. Drain lubricant into suitable container. See
Figure 1-7. Fill Primary Chaincase With Lubricant
Figure 1-5.
3. Clean drain plug. If plug has accumulated a lot of debris,
inspect the condition of chaincase components.
b.
Insert screw (with captive washer) through clutch
inspection cover and carefully thread it all the way
4. Inspect drain plug O-ring for cuts, tears or signs of dete-
through triangular shaped hole in gasket. Do not
rioration. Replace as necessary.
push screw through hole.
5. Install drain plug back into primary chaincase cover.
c.
Hang the clutch inspection cover on the primary
Tighten plug to 36-60 in-lbs (4.1-6.8 Nm).
chaincase cover flange by starting the top cover
screw.
CAUTION
d.
Start the remaining four screws (with captive wash-
ers).
Do not overfill the primary chaincase with lubricant.
Overfilling may cause rough clutch engagement, incom-
e.
Using a T27 TORX drive head, alternately tighten
plete disengagement, clutch drag and/or difficulty in
screws to 84-108 in-lbs (10-12 Nm) in the pattern
finding neutral at engine idle.
shown in Figure 1-5.
1WARNING
Be sure that lubricant does not contact rear wheel, tire
and brake components. Such contact can adversely
affect traction and may lead to loss of vehicle control,
which could result in death or serious injury.
6. Pour 32 ounces (946 ml) of Harley-Davidson PRIMARY
CHAINCASE LUBRICANT through the clutch inspection
cover opening, Part No. 99887-84 (quart) or Part No.
99886-84 (gallon). See Figure 1-7.
7. To avoid punching holes in the clutch inspection cover
gasket or enlarging existing holes, install clutch inspec-
tion cover and new gasket as follows:
a. Align the triangular shaped hole in the gasket with
the top hole in the clutch inspection cover. Be sure
the rubber molding and the words “towards clutch”
face the motorcycle.
1-16
2005 Touring: Maintenance
HOME
CLUTCH ADJUSTMENT
1.8
GENERAL
Adjust for 1/16-1/8 inch
(1.6-3.2 mm) gap
See Section
1.2 MAINTENANCE SCHEDULE for the
between ferrule
Clutch
required service interval.
and bracket
Cable
PROCEDURE
CAUTION
Perform the clutch adjustment with the motorcycle at
room temperature. The clearance at the adjuster screw
will increase as the powertrain temperature increases. If
Ferrule
adjuster screw is adjusted while the powertrain is hot,
Clutch Lever
f1421x6x
clearance at push rod bearing could be insufficient with
Bracket
powertrain cold and clutch slippage could occur.
Figure 1-9. Adjust Clutch Free Play
NOTE
Perform adjustment procedure whenever any clutch compo-
nents are replaced. Then repeat adjustment after first 500
f1509b6x
Clutch
miles (800 km) of use.
Adjuster
Screw
1. Stand motorcycle upright and level.
2. Using a T27 TORX drive head, remove five screws (with
captive washers) to free clutch inspection cover from pri-
mary chaincase cover.
3. See Figure 1-8. Slide rubber boot off cable adjuster.
Holding cable adjuster with 1/2 inch wrench, loosen jam
nut using a 9/16 inch wrench. Back jam nut away from
cable adjuster. Move adjuster toward jam nut to intro-
duce a large amount of free play at hand lever.
4. See Figure
1-10. Loosen locknut on clutch adjuster
screw. To take up all free play in push rods, turn screw
inward (clockwise) until lightly seated.
5. Back out adjuster screw 1/2 to 1 turn. While holding
adjuster screw with an allen wrench, tighten locknut to
72-120 in-lbs (8-14 Nm).
Locknut
f1440x6x
Figure 1-10. Clutch Assembly
Jam
Nut
Rubber
6.
Squeeze clutch lever to maximum limit three times to set
Boot
ball and ramp release mechanism.
Cable
7.
Turn cable adjuster away from jam nut until slack is elim-
End
inated at hand lever. Pull clutch cable ferrule away from
Cable
clutch lever bracket to check free play. Turn cable
Adjuster
adjuster as necessary to obtain 1/16 to 1/8 inch (1.6-3.2
mm) free play between end of cable ferrule and clutch
lever bracket, as shown in Figure 1-9.
Figure 1-8. Clutch Cable Adjuster Mechanism
2005 Touring: Maintenance
1-17
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